Cross-over Pipe Fuel Leak
Thread Starter
Drifting
Joined: Jul 2000
Posts: 1,661
Likes: 4
From: Phoenix, Arizona
Cross-over Pipe Fuel Leak
Our 2004 Z06 is leaking fuel from the left (driver) side of the cross-over. I've been told by one source that this is rare, but known. Also that the cross-over is rigid on 2004s instead of flexible as on earlier ones. We autocross this car a fair amount, so I am imagining that movement may be the culprit. I am pretty sure the tanks have to come out to make the fix. And, it leaks directly on to the exhaust pipe - so it's parked. Question, has anyone else had this problem? What was a permanent solution? Can an earlier (97-03) corss-over pipe be used that is flexible? Thanks a lot, Paul 
Le Mans Master
Joined: Sep 2003
Posts: 6,276
Likes: 227
From: Farmington CT
Cruise-In VII Veteran
the later half of the '03 cars also have the FFS tanks, i think the vin is 114930 and later for the new tanks
I have no experience with this leaking problem, just noting that FFS was introduced mid year '03
I have no experience with this leaking problem, just noting that FFS was introduced mid year '03
Racer
Joined: Sep 2004
Posts: 486
Likes: 1
From: Houston TX
Do a search for fuel tank leaks. My '04 coupe had one and needed the drivers tank to be replaced. There seems to be an issue with the driver's side tank for some reason. I had COH do mine, and they reported that after they put the new tank in they could tell the difference when the crossover tube was attached. They did the job twice. On the first go around, they only replaced the seals for the crossover tube and sender unit. But after more investigation because the unit still leaked, they finally replaced the tank. Fortunately, they did the right thing and only charged me and Warranty Direct once for labor - but I was without those wheels for 2.5 weeks.
- Wisdom
- Wisdom
Melting Slicks
Joined: Apr 1999
Posts: 2,988
Likes: 22
From: New Lebanon.Ohio
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I had the same problem on my 04-Z06, second tank of gas when it was new,June 04. It was leaking so bad the dealer sent a flat bed to pick it up. They replaced the drivers side tank and cross over pipe. No problems since, there were other O4's with the same problem at the time. I think the reason was defective driver side tanks where the crossover attaches.
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Instructor
Joined: Dec 2005
Posts: 171
Likes: 0
From: Gainesville Florida
I think I may have this problem. Seems like it leaks when I fill the tank. As the tank goes down, no gas smell in the garage. I didn't know it may be leaking on the muffler - WOW! I need to park this baby now.....
Racer
Joined: Sep 2004
Posts: 486
Likes: 1
From: Houston TX
Don't worry about leaking on the muffler. If you drive fast enough and the gas catches on fire, the flames will be behind you and you'll only be feeding it. Besides, it'll look really cool going down the highway! It will be more realistic than some of those painted flames!
- Wisdom
- Wisdom
Instructor
Joined: Dec 2005
Posts: 171
Likes: 0
From: Gainesville Florida
Crossover pipe
My 04 is at the dealership right now. Took it in on Wednesday last week. I did have a leak in the gas tank at the crossover pipe. They have ordered a new tank, filler tube and crossover pipe. While they were looking, they discovered a leak in the rear differential. When I stopped at the dealership on Friday, they were taking the rear of the vehicle apart to repair the differential, other parts had not arrived yet. They have put me in a rental (Chevy van). Frankly, it's been a very lonesome weekend - I miss my car. Usually in the garage detailing something on Saturday. I'll be stopping by Palm Chevrolet on Monday just to say "Hi" to my vette and to see how they are doing on it. I met the 2 mechanics working on it, they really seemed like committed guys. They showed me around, I could see the leak area in the tank and in the rear differential. Hopefully, things will be okay by next weekend.
Instructor
Joined: Aug 2004
Posts: 179
Likes: 0
From: Surprise Az
FWIW I had this problem on an '03 Z. They replaced the tank and crossover pipe and it took two weeks to get the parts in.
It's obvious when you have this problem - strong gasoline smell in the garage.
It's obvious when you have this problem - strong gasoline smell in the garage.
Has anyone taken a poll?
I hope this isnot another time bomb like the window motors or the headlight gears!
Instructor
Joined: Dec 2005
Posts: 171
Likes: 0
From: Gainesville Florida
It appears I will be looking at approx 2 weeks as well. The tank came in today, the crossover pipe is on backorder. It may not come in until late this week - maybe not until next week. Dealership says they get a high priority since they have me in a rental. They state they won't pull the rental, but I miss my vette. The seal in the rear differential was repaired. Since the car is in so many parts, they have left it in the bay. At least it's inside. I expect rain over the next few days.
Just a thought..... I purchased some Z06 ti mufflers and they are not installed. I wonder if the dealership would put them on in place of the standard ones???? I'll have to check on that.
Just a thought..... I purchased some Z06 ti mufflers and they are not installed. I wonder if the dealership would put them on in place of the standard ones???? I'll have to check on that.
Intermediate
Joined: Oct 2006
Posts: 33
Likes: 0
From: Powhatan Virginia
fuel smell
I have the same thing with my 01 I ran an evap test found leak in right fuel tank were cross over pipe hooks to tank took carpet out of back removed 2 panels with hot knive, cracked crossover pipe part will be here tomorrow from gm 
Racer
Joined: Sep 2004
Posts: 486
Likes: 1
From: Houston TX
I don't know how many '04's have that problem, but there seems to be quite a few if you read the posts. I'm sure that not everyone that has the problem was aware of others or that the forums exist. But it would be nice to find out if GM wants to do a recall on them - I've got receipts!
- Wisdom
- Wisdom
Melting Slicks
Joined: Jan 2004
Posts: 3,012
Likes: 15
From: Jensen Beach FL
I noticed a gas smell in my garage last night. Today I noticed a gas leak under the drivers side under the filler tube. I am going in to the dealer tomorrow to have them check it out. Hope it's just the filler tube to tank and not the crossover pipe. I don't want them taking the rear cradle apart.
